Scope of this check-list is to evaluate how far your company is to be a “Lean Company”
After this Audit Check-List, plan how to implement the missing points
1º Get management commitment
1) Do we have a Lean manager?
2) Does the Lean manager have top management support to execute change?
Yes/No
Yes/No
2º Determine a product line
3) Have we determined a product line or plant area to start the pilot phase?
Yes/No
4) Does the product line chosen part of the 20% that generate 80% of revenues? Yes/No
3º Understand lean techniques
3.1 “5 S”
5) Do we know what means 5S?
6) Do we have already 5S in the plant?
Yes/No
Yes/No
3.2 Demand
7) Do we know how to calculate takt time? (try test on www.leanlab.info)
8) Do we have stable production to work at takt time?
9) Do we have buffer and safety stocks?
10) Do we use supermarkets to replenish parts into 80/20?
Yes/No
Yes/No
Yes/No
Yes/No
3.3 Flow
11) Are we working in U shape cells?
12) Do we have a levelled line to reduce each step time spent?
13) Do we use pull process?
14) Do we use kanban cards to replenish?
15) Do we use a runner to replenish kanban?
16) Do we use standardized processes?
17) Are the standard processes available in the working areas?
18) Are the standard processes updated?
19) Do we have a materials continuous flow?
20) Do we have bottle necks in the plant?
21) Do we have visual control in the plant?
22) Do we have an standardized training plan for each new employee?
23) Do we have an experienced trainer?
24) Do we have a cross training process to get a flexible team?
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
3.4 Levelling
25) Do we have a system to level work load?
26) Do we use heijunka boxes?
Yes/No
Yes/No
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3.5 Kaizen
27) Do we have an standardized process for continuous improvement?
28) Do the employees participate?
29) Do we have a system that permit employees and managers work together in
continuous improvement?
30) Do we have kaizen events regularly?
31) Do we use SMED techniques to reduce change over time?
32) Do we have a standardized employees suggestions program?
33) Are the employees participating in that program?
34) Do we execute employees suggestions?
35) Do we inform employees frequently about the suggestions state?
Approved vs. Rejected.
36) Do we have 5 minutes meeting before shift starts?
37) Do we have an information system that permit employees
explain problems detected today?
38) Is that information system checked every day?
3.6 Continuous Improvement
39) Do we have incentive for employees to participate
in continuous improvement?
40) Do we have teams in charge of continuous improvement?
3.7 TPM
41) Do we have a preventive maintenance calendar?
42) Do we use it properly?
43) Are the employees participating in that program?
44) Do we have a low breakdown percentage?
45) Do we have standardize process to maintain equipments,
tools, machines and dies in good shape?
46) Do we use the standard process?
47) Is the preventive maintenance working well?
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
4° Create the current state map
48) Do we have a current state map?
49) Have been the map updated in the last 3 months?
50) Have we physically measured the cycle time, lead time, work in process
and machinery uptime?
51) Do we know where are the bottle necks and bigger problems?
Yes/No
Yes/No
Yes/No
Yes/No
5° Define lean metrics
52) Have we defined lean metrics to check results?
53) Are we checking results every day? Every shift?
54) Do we have defined counter measures in case of deviations?
55) Is each responsible person checking metrics daily?
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Yes/No
Yes/No
Yes/No
Yes/No
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6° Create future state map
56) Do we have a future state map?
57) Do we have a defined plan (What, Who, When) to define changes?
58) Are we executing actions on time?
Yes/No
Yes/No
Yes/No
7° Gemba & PDCA
59) Are the responsible persons passing the majority of their time
in the plant checking problems?
60) Do we have fluent communication between employees and
managers to resolve problems?
61) Do we have a PDCA process? (Plan-Do-Check-Act)
Yes/No
Yes/No
Yes/No
If you note a lot of “No” you are in Critical Situation and you have to arrange with
your team, urgent action to solve the problems and implement stable solutions.
Date of Audit
______/_____/_______
Audit Score (n° of yes) ____ /
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Next Planned Audit (Suggested max 2 months later)
_____/______/_______
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